open gas tank JEEP LIBERTY 2002 KJ / 1.G Workshop Manual

CONDITION POSSIBLE CAUSES CORRECTION
6. Cylinder head gasket leaking
allowing exhaust gas to enter
cooling system causing a
thermostat to open late.6. (a) Check for cylinder head
gasket leaks. (Refer to 7 -
COOLING - DIAGNOSIS AND
TESTING).
(b) Check for coolant in the engine
oil. Inspect for white steam emitting
from the exhaust system. Repair as
necessary.
7. Water pump impeller loose on
shaft.7. Check water pump and replace
as necessary. (Refer to 7 -
COOLING/ENGINE/WATER PUMP -
DIAGNOSIS AND TESTING).
8. Loose accessory drive belt.
(water pump slipping)8. (Refer to 7 - COOLING/
ACCESSORY DRIVE/DRIVE BELTS
- DIAGNOSIS AND TESTING).
Check and correct as necessary.
9. Air leak on the suction side of
the water pump allows air to build
up in cooling system causing
thermostat to open late.9. Locate leak and repair as
necessary.
PRESSURE CAP IS BLOWING
OFF STEAM AND/OR COOLANT
TO COOLANT TANK.
TEMPERATURE GAUGE READING
MAY BE ABOVE NORMAL BUT
NOT HIGH. COOLANT LEVEL MAY
BE HIGH IN COOLANT RESERVE/
OVERFLOW TANK1. Pressure relief valve in pressure
bottle cap is defective.1. Check condition of radiator cap
and cap seals. (Refer to 7 -
COOLING/ENGINE/RADIATOR
PRESSURE CAP - DIAGNOSIS
AND TESTING). Replace cap as
necessary.
COOLANT LOSS TO THE
GROUND WITHOUT PRESSURE
CAP BLOWOFF. GAUGE READING
HIGH OR HOT1. Coolant leaks in radiator, cooling
system hoses, water pump or
engine.1. Pressure test and repair as
necessary. (Refer to 7 - COOLING -
DIAGNOSIS AND TESTING).
DETONATION OR PRE-IGNITION
(NOT CAUSED BY IGNITION
SYSTEM). GAUGE MAY OR MAY
NOT BE READING HIGH1. Engine overheating. 1. Check reason for overheating
and repair as necessary.
2. Freeze point of coolant not
correct. Mixture is too rich or too
lean.2. Check coolant concentration.
(Refer to 7 - COOLING/ENGINE/
COOLANT - DESCRIPTION) and
adjust ratio as required.
KJCOOLING 7 - 9
COOLING (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
TEMPERATURE GAUGE READING
IS INCONSISTENT (FLUCTUATES,
CYCLES OR IS ERRATIC)1. During cold weather operation,
with the heater blower in the high
position, the gauge reading may
drop slightly.1. A normal condition. No correction
is necessary.
2. Temperature gauge or engine
mounted gauge sensor defective or
shorted. Also, corroded or loose
wiring in this circuit.2. Check operation of gauge and
repair if necessary. Refer to Group
8J, Instrument cluster.
3. Gauge reading rises when
vehicle is brought to a stop after
heavy use (engine still running)3. A normal condition. No correction
is necessary. Gauge should return
to normal range after vehicle is
driven.
4. Gauge reading high after
re-starting a warmed up (hot)
engine.4. A normal condition. No correction
is necessary. The gauge should
return to normal range after a few
minutes of engine operation.
5. Coolant level low in cooling
system (air will build up in the
cooling system causing the
thermostat to open late).5. Check and correct coolant leaks.
(Refer to 7 - COOLING -
DIAGNOSIS AND TESTING).
6. Cylinder head gasket leaking
allowing exhaust gas to enter
cooling system causing a
thermostat to open late.6. (a) Check for cylinder head
gasket leaks. (Refer to 7 -
COOLING - DIAGNOSIS AND
TESTING).
(b) Check for coolant in the engine
oil. Inspect for white steam emitting
from the exhaust system. Repair as
necessary.
7. Water pump impeller loose on
shaft.7. Check water pump and replace
as necessary. (Refer to 7 -
COOLING/ENGINE/WATER PUMP -
DIAGNOSIS AND TESTING).
8. Loose accessory drive belt.
(water pump slipping)8. (Refer to 7 - COOLING/
ACCESSORY DRIVE/DRIVE BELTS
- DIAGNOSIS AND TESTING).
Check and correct as necessary.
9. Air leak on the suction side of
the water pump allows air to build
up in cooling system causing
thermostat to open late.9. Locate leak and repair as
necessary.
PRESSURE CAP IS BLOWING
OFF STEAM AND/OR COOLANT
TO COOLANT TANK.
TEMPERATURE GAUGE READING
MAY BE ABOVE NORMAL BUT
NOT HIGH. COOLANT LEVEL MAY
BE HIGH IN COOLANT RESERVE/
OVERFLOW TANK1. Pressure relief valve in pressure
bottle cap is defective.1. Check condition of radiator cap
and cap seals. (Refer to 7 -
COOLING/ENGINE/RADIATOR
PRESSURE CAP - DIAGNOSIS
AND TESTING). Replace cap as
necessary.
7s - 8 COOLING - 2.4LKJ
COOLING - 2.4L (Continued)

FUEL PUMP
DESCRIPTION
The electric fuel pump is located inside of the fuel
pump module. A 12 volt, permanent magnet, electric
motor powers the fuel pump. The electric fuel pump
is not a separate, serviceable component.
OPERATION
Voltage to operate the electric pump is supplied
through the fuel pump relay.
Fuel is drawn in through a filter at the bottom of
the module and pushed through the electric motor
gearset to the pump outlet.
Check Valve Operation:The bottom section of
the fuel pump module contains a one-way check
valve to prevent fuel flow back into the tank and to
maintain fuel supply line pressure (engine warm)
when pump is not operational. It is also used to keep
the fuel supply line full of gasoline when pump is not
operational. After the vehicle has cooled down, fuel
pressure may drop to 0 psi (cold fluid contracts), but
liquid gasoline will remain in fuel supply line
between the check valve and fuel injectors.Fuel
pressure that has dropped to 0 psi on a cooled
down vehicle (engine off) is a normal condition.
Refer to the Fuel Pressure Leak Down Test for more
information.
The electric fuel pump is not a separate, service-
able component.
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - FUEL PUMP
CAPACITY TEST
Before performing this test, verify fuel pump
pressure. Refer to Fuel Pump Pressure Test.
Use this test in conjunction with the Fuel Pres-
sure Leak Down Test.
(1) Release fuel system pressure. Refer to Fuel
Pressure Release Procedure.
(2) Disconnect fuel supply line at fuel rail. Refer to
Quick-Connect Fittings. Some engines may require
air cleaner housing removal before line disconnection.
(3) Obtain correct Fuel Line Pressure Test Adapter
Tool Hose. Tool number 6539 is used for 5/16º fuel
lines and tool number 6631 is used for 3/8º fuel lines.
(4) Connect correct Fuel Line Pressure Test
Adapter Tool Hose into disconnected fuel supply line.
Insert other end of Adaptor Tool Hose into a gradu-
ated container.
(5) Remove fuel fill cap.(6) To activate fuel pump and pressurize system,
obtain DRBtscan tool and actuate ASD Fuel System
Test.
(7) A good fuel pump will deliver at least 1/10 liter
of fuel in 7 seconds. Do not operate fuel pump for
longer than 7 seconds with fuel line disconnected as
fuel pump module reservoir may run empty.
(a) If capacity is lower than specification, but
fuel pump can be heard operating through fuel fill
cap opening, check for a kinked/damaged fuel sup-
ply line somewhere between fuel rail and fuel
pump module.
(b) If line is not kinked/damaged, and fuel pres-
sure is OK, but capacity is low, replace fuel filter.
Refer to Fuel Filter Removal/Installation for addi-
tional information.
(c) If both fuel pressure and capacity are low,
replace bottom section of fuel pump module. Refer
to Fuel Pump Module Removal/Installation.
DIAGNOSIS AND TESTING - FUEL PUMP
PRESSURE TEST
Use this test in conjunction with the Fuel Pump
Capacity Test, Fuel Pressure Leak Down Test and
Fuel Pump Amperage Test found elsewhere in this
group.
Check Valve Operation:The bottom section of
the fuel pump module contains a one-way check
valve to prevent fuel flow back into the tank and to
maintain fuel supply line pressure (engine warm)
when pump is not operational. It is also used to keep
the fuel supply line full of gasoline when pump is not
operational. After the vehicle has cooled down, fuel
pressure may drop to 0 psi (cold fluid contracts), but
liquid gasoline will remain in fuel supply line
between the check valve and fuel injectors.Fuel
pressure that has dropped to 0 psi on a cooled
down vehicle (engine off) is a normal condition.
When the electric fuel pump is activated, fuel pres-
sure shouldimmediately(1±2 seconds) rise to spec-
ification.
The fuel system is equipped with a separate fuel
pump module mounted, fuel pressure regulator. The
fuel filter is remotely mounted. The fuel pressure
regulator is not controlled by engine vacuum.
WARNING: THE FUEL SYSTEM IS UNDER CON-
STANT FUEL PRESSURE EVEN WITH THE ENGINE
OFF. BEFORE DISCONNECTING FUEL LINE AT
FUEL RAIL, THIS PRESSURE MUST BE RELEASED.
REFER TO THE FUEL SYSTEM PRESSURE
RELEASE PROCEDURE.
KJFUEL DELIVERY 14 - 15

(17) When LCS adapter test leads are attached
into relay cavities, fuel pumpwill be activated.
Determine fuel pump amperage on DRB screen.
Amperage should be below 10.0 amps. If amperage is
below 10.0 amps, and specifications for the Fuel
Pump Pressure, Fuel Pump Capacity and Fuel Pres-
sure Leak Down tests were met, the fuel pump mod-
ule is OK.
(18) If amperage is more than 10.0 amps, replace
fuel pump module assembly. The electric fuel pump
is not serviced separately.
(19) Disconnect test leads from relay cavities
immediately after testing.
FUEL PUMP MODULE
DESCRIPTION
The fuel pump module assembly is located in the
fuel tank (Fig. 1). The assembly is divided into 2±sec-
tions, upper and lower. The lower section is locked to
the bottom of the fuel tank. The complete assembly
contains the following components:
²A fuel pressure regulator
²A separate fuel pick-up, or inlet filter
²An electric fuel pump
²A lockring to retain upper section of pump mod-
ule to tank
²A rollover valve
²A vent fitting for ORVR system
²A soft gasket between tank flange and module
²A fuel gauge sending unit (fuel level sensor)
²Two fuel line connections (supply and return)
The fuel gauge sending unit may be serviced sepa-
rately. If the electrical fuel pump, primary inlet filter
or fuel pressure regulator require service, the lower
section of the fuel pump module must be replaced.
OPERATION
Refer to Fuel Pump, Inlet Filter, Fuel Pressure
Regulator and Fuel Gauge Sending Unit.
REMOVAL
The fuel pump module is divided into 2 sections,
upper and lower. To service the check (control) valve,
replace only the upper section. To service the fuel
gauge sending unit, remove the upper section. To ser-
vice the electric fuel pump, fuel pressure regulator or
primary inlet filter, remove both sections and replace
lower section.
Fuel tank removal will not be necessary for
fuel pump module removal. Access is from rear
cargo area.
(1) Four cargo holdown clamps are located inside
the vehicle on the floor of the rear cargo area.Remove the 2 rearward mounted clamps by drilling
out the clamp rivets.
(2) Fold carpeting forward to gain access to fuel
pump module access plate (Fig. 25).
(3) Remove 4 fuel pump module access plate nuts
(Fig. 25).
(4) While applying heat from a heat gun, carefully
pry up fuel pump module access plate. Take care not
to bend plate.
(5) Thoroughly clean area around top of pump
module to prevent contaminants from entering fuel
tank or fuel lines.
WARNING: THE FUEL SYSTEM IS UNDER A CON-
STANT PRESSURE EVEN WITH ENGINE OFF.
BEFORE SERVICING THE FUEL PUMP MODULE,
FUEL SYSTEM PRESSURE MUST BE RELEASED.
(6) Release fuel system pressure. Refer to Fuel
System Pressure Release procedure.
(7) Disconnect 2 fuel lines at fuel pump module
(Fig. 26) by pressing on 2 buttons at sides of fitting.
(8) Disconnect electrical connector (Fig. 26) at top
of fuel pump module by sliding red colored tab first
to unlock, and push grey colored tab down for
removal.
(9) Disconnect ORVR hose clamp and hose (Fig.
26) at pump module fitting.
(10) Remove module lockring (Fig. 26) using a
brass drift and hammer (counter-clockwise).
(11) Carefully lift upper section of pump module
(Fig. 26) from fuel tank exposing connections(lift
upper section from tank very slowly until rub-
ber gasket can be retained. If not, gasket will
fall into fuel tank.)
(a) Disconnect electrical connector (Fig. 27) at
bottom of upper pump module section.
(b) Disconnect fuel pressure regulator (Fig. 27)
at bottom of upper pump module section. Press on
2 locking tabs.
(c) Disconnect fuel return line (Fig. 27) at bot-
tom of upper pump module section. Press on 2
locking tabs.
(d) Remove upper section of pump module (Fig.
28) from fuel tank.
(12) Using an approved gas holding tank, drain
fuel tank through pump module opening.If check
(control) valve, or, only upper section of pump
module is being serviced, tank draining is not
necessary. If any other fuel pump module com-
ponent is being serviced, the tank must be com-
pletely drained to the bottom.
(13) To remove lower section of pump module from
fuel tank:
(a) Using finger pressure, push on plastic
release tab (Fig. 29) while sliding lock tab upward.
14 - 18 FUEL DELIVERYKJ
FUEL PUMP (Continued)

(b) The sides of pump module are equipped with
tension springs (Fig. 29). These springs hold mod-
ule to bottom of fuel tank into 2 formed guides
(Fig. 30). Release module assembly from these 2
guides by sliding toward right side of fuel tank.
(c) Lift assembly from fuel tank.
INSTALLATION
CAUTION: Whenever fuel pump module is serviced,
pump module gasket must be replaced.
(1) Position lower section of fuel pump module
assembly into fuel tank.
(2) The bottom of fuel tank has 2 formed guides.
Lock module assembly into these 2 guides by sliding
toward left side of fuel tank.
(3) Push down on plastic tab to lock module to fuel
tank guides.
(4) Connect fuel supply line to bottom of upper
pump module section.
(5) Connect fuel pressure regulator to bottom of
upper pump module section.
(6) Connect electrical connector to bottom of upper
pump module section.
(7) Position pump module into fuel tank. Notch on
module must be facing rear of tank.(8) Position lock ring to module. Tap lockring
using a brass drift and hammer (clockwise) until
rotated up to built-on stops.
(9) Attach (snap on) 2 fuel filter fuel lines to top of
fuel pump module.
(10) Connect hoses/lines to ORVR components.
(11) Fill fuel tank with fuel.
(12) Start engine and check for fuel leaks.
(13) Apply silicone sealant to bottom of fuel pump
module metal access plate.
(14) Install fuel pump module metal access plate
and 4 nuts. Tighten nuts to 3 N´m (26 in. lbs.)
torque.
(15) Position carpet and install 2 new cargo clamp
rivets into each cargo holdown clamp.
Fig. 25 ACCESS PLATE
1 - FLOORPAN AT REAR
2 - FUEL PUMP MODULE ACCESS PLATE
3 - NUTS (4)
4 - OPENING TO PUMP MODULE
Fig. 26 TOP OF FUEL PUMP MODULE
1 - LOCK RING
2 - ALIGNMENT NOTCH
3 - FUEL FILTER FITTINGS (2)
4 - ORVR SYSTEM HOSE AND CLAMP
5 - FLOW MANAGEMENT VALVE
6 - ELECTRICAL CONNECTOR
7 - LEAK DETECTION PUMP
8 - FUEL TANK CHECK (CONTROL) VALVE
9 - FUEL PUMP MODULE (UPPER SECTION)
KJFUEL DELIVERY 14 - 19
FUEL PUMP MODULE (Continued)

REMOVAL
Fuel Tank Draining
WARNING: THE FUEL SYSTEM MAY BE UNDER
CONSTANT FUEL PRESSURE EVEN WITH THE
ENGINE OFF. THIS PRESSURE MUST BE
RELEASED BEFORE SERVICING FUEL TANK.
Two different procedures may be used to drain fuel
tank: removing fuel pump module access plate, or
using DRBtscan tool. Due to a one-way check valve
installed into the fuel fill opening fitting at the tank
(Fig. 38), the tank cannot be drained conventionally
at the fill cap.
The quickest draining procedure involves removing
fuel pump module access plate.
As an alternative procedure, the electric fuel pump
may be activated allowing tank to be drained at fuel
rail connection. Refer to DRB scan tool for fuel pump
activation procedures. Before disconnecting fuel line
at fuel rail, release fuel pressure. Refer to the Fuel
System Pressure Release Procedure for procedures.
Attach end of special test hose tool number 6541,
6539, 6631 or 6923 at fuel rail disconnection (tool
number will depend on model and/or engine applica-
tion). Position opposite end of this hose tool to an
approved gasoline draining station. Activate fuel
pump and drain tank until empty.
If electric fuel pump is not operating, fuel pump
module access plate must be removed for fuel drain-
ing. Refer to following procedures.Fuel tank removal will not be necessary for
fuel tank draining. Access for draining is from
rear cargo area.
(1) Open all windows in vehicle to allow for air
ventilation.
(2) Four cargo holdown clamps are located inside
the vehicle on the floor of the rear cargo area.
Remove the 2 rearward mounted clamps by drilling
out the clamp rivets.
(3) Fold carpeting forward to gain access to fuel
pump module access plate (Fig. 39).
(4) Remove 4 fuel pump module access plate nuts
(Fig. 39).
(5) While applying heat from a heat gun, carefully
pry up fuel pump module access plate. Take care not
to bend plate.
(6) Thoroughly clean area around top of pump
module to prevent contaminants from entering fuel
tank or fuel lines.
(7) Release fuel system pressure.
(8) Disconnect 2 fuel lines (Fig. 40) at fuel pump
module by pressing on tabs at side of fitting.
(9) Disconnect electrical connector (Fig. 40). Slide
red tab first to unlock, and push grey tab down for
removal.
(10) Disconnect ORVR hose (Fig. 40) at pump mod-
ule fitting.
Fig. 38 FUEL FILL CHECK VALVE
1 - ONE-WAY CHECK VALVE
2 - FUEL FILL FITTING
3 - SIDE OF FUEL TANK
Fig. 39 ACCESS PLATE
1 - FLOORPAN AT REAR
2 - FUEL PUMP MODULE ACCESS PLATE
3 - NUTS (4)
4 - OPENING TO PUMP MODULE
KJFUEL DELIVERY 14 - 25
FUEL TANK (Continued)

(11) Remove module lockring (Fig. 40) using a
brass drift and hammer (counter-clockwise).
(12) Carefully lift upper section of pump module
from fuel tank a few inches(lift upper section
from tank very slowly until rubber gasket can
be retained. If not, gasket will fall into fuel
tank).
(13) Using an approved gas holding tank, drain
fuel tank through fuel pump module opening.
Tank Removal
(1) After draining tank, temporarily place upper
section of fuel pump module back into fuel tank.
(2) Raise vehicle.
(3) If equipped, remove fuel tank skid plate and
tow hooks. Certain equipment packages will also
require removal of the trailer hitch. Refer to Tow
Hooks, Trailer Hitch or Skid Plate in 23, Body for
removal/installation procedures.
(4) Disconnect fuel filter ground strap.
(5) Disconnect fuel filter outlet line from body
retention clip located on frame near front/center of
tank (Fig. 41). Place a small screwdriver into side of
clip and twist for removal. Also disconnect Leak
Detection Pump (LDP) line (Fig. 41) from this clip.(6) Remove both 3/4º hoses at sides of Leak Detec-
tion Pump (LDP) (Fig. 41).
(7) Disconnect 3/4º flow management valve hose
(Fig. 41) at EVAP canister.
(8) Remove fuel fill hose clamp (Fig. 42) at fuel
tank, and disconnect hose from fuel tank.
(9) A third fuel line is attached to bottom of fuel
filter. The disconnection point (quick-connect fitting)
for this 3rd line is approximately 1 foot from front of
tank towards front of vehicle (Fig. 41). Clean connec-
tion point before disconnection. Disconnect by press-
ing on tabs at side of quick-connect fitting. Also
disconnect LDP vent line near this same point.
(10) Disconnect 2 vacuum/vent hoses from plastic
retention clip at left/front of fuel tank line (Fig. 41).
(11) Support tank with a hydraulic jack.
(12) Remove 4 fuel tank strap bolts (Fig. 41) (2 at
front of tank; 2 at rear of tank), and remove both
tank support straps (Fig. 41).
(13) Carefully lower tank a few inches and discon-
nect electrical connector at top of LDP (Fig. 43). To
disconnect electrical connector: Push upward on red
colored tab to unlock. Push on black colored tab
while removing connector.
Fig. 40 TOP OF FUEL PUMP MODULE
1 - LOCK RING
2 - ALIGNMENT NOTCH
3 - FUEL FILTER FITTINGS (2)
4 - ORVR SYSTEM HOSE AND CLAMP
5 - FLOW MANAGEMENT VALVE
6 - ELECTRICAL CONNECTOR
7 - LEAK DETECTION PUMP
8 - FUEL TANK CHECK (CONTROL) VALVE
9 - FUEL PUMP MODULE (UPPER SECTION)Fig. 41 FRONT OF FUEL TANK
1 - TANK MOUNTING BOLTS (4)
2 - TANK MOUNTING STRAPS (2)
3 - LEAK DETECTION PUMP (LDP)
4 - BODY RETENTION CLIP (CENTER)
5 - LDP HOSES
6 - HOSE TO FUEL MANAGEMENT VALVE
7 - BODY RETENTION CLIP (LEFT/FRONT)
8 - QUICK-CONECT FITTING
9 - LDP LINE
14 - 26 FUEL DELIVERYKJ
FUEL TANK (Continued)

FUEL PRESSURE REGULATOR -
DESCRIPTION.......................14-13
FUEL PRESSURE REGULATOR -
INSTALLATION.......................14-14
FUEL PRESSURE REGULATOR -
OPERATION.........................14-14
FUEL PRESSURE REGULATOR -
REMOVAL..........................14-14
FUEL PUMP - DESCRIPTION............14-15
FUEL PUMP - OPERATION.............14-15
FUEL PUMP AMPERAGE TEST -
DIAGNOSIS AND TESTING.............14-16
FUEL PUMP CAPACITY TEST -
DIAGNOSIS AND TESTING.............14-15
FUEL PUMP MODULE - DESCRIPTION....14-18
FUEL PUMP MODULE - INSTALLATION . . . 14-19
FUEL PUMP MODULE - OPERATION......14-18
FUEL PUMP MODULE - REMOVAL.......14-18
FUEL PUMP PRESSURE TEST -
DIAGNOSIS AND TESTING.............14-15
FUEL PUMP RELAY - DESCRIPTION......14-34
FUEL PUMP RELAY - DIAGNOSIS AND
TESTING...........................14-34
FUEL PUMP RELAY - INSTALLATION.....14-34
FUEL PUMP RELAY - OPERATION........14-34
FUEL PUMP RELAY - REMOVAL.........14-34
FUEL PUMP RELAYS - DIAGNOSIS AND
TESTING, ASD........................8I-4
FUEL RAIL - DESCRIPTION.............14-21
FUEL RAIL - INSTALLATION..............14-24
FUEL RAIL - OPERATION...............14-21
FUEL RAIL - REMOVAL................14-22
FUEL SYSTEM PRESSURE RELEASE -
STANDARD PROCEDURE................14-4
FUEL SYSTEM PRESSURE,
SPECIFICATIONS......................14-5
FUEL SYSTEM, SPECIAL TOOLS..........14-6
FUEL TANK - DESCRIPTION............14-24
FUEL TANK - INSTALLATION............14-27
FUEL TANK - OPERATION..............14-24
FUEL TANK - REMOVAL...............14-25
FUEL TANK CHECK VALVE -
DESCRIPTION.......................14-28
FUEL TANK CHECK VALVE -
INSTALLATION.......................14-28
FUEL TANK CHECK VALVE - OPERATION . . 14-28
FUEL TANK CHECK VALVE - REMOVAL....14-28
FUEL TANK SKID PLATE - INSTALLATION . . . 13-9
FUEL TANK SKID PLATE - REMOVAL......13-9
FULL TIME INDICATOR - DESCRIPTION . . . 8J-29
FULL TIME INDICATOR - OPERATION.....8J-30
FUNCTION - DIAGNOSIS AND TESTING,
REAR HVAC CONTROL ASSEMBLY
WINDOW DEFOGGER..................8G-9
FUNCTIONS - DESCRIPTION, CIRCUIT . . 8W-01-6
FUSE - DESCRIPTION, IOD...........8W-97-3
FUSE - INSTALLATION, IOD..........8W-97-3
FUSE - OPERATION, IOD.............8W-97-3
FUSE - REMOVAL, IOD..............8W-97-3
FUSES POWERING SEVERAL LOADS -
STANDARD PROCEDURE, TESTING
FOR A SHORT TO GROUND ON.......8W-01-9
GALLERY PLUGS - STANDARD
PROCEDURE, ENGINE CORE AND OIL.....9-10
GAP AND FLUSH - SPECIFICATIONS.....23-116
GAS ENGINES - GENERATOR RATINGS....8F-23
GAS POWERED - STARTER MOTOR......8F-39
GAS POWERED - TORQUE
.............8F-38
GASKET - DIAGNOSIS AND TESTING,
CYLINDER HEAD
..................9-19,9-30
GASKET SURFACE PREPARATION -
STANDARD PROCEDURE, ENGINE
.........9-9
GATE - INSTALLATION, SWING
.........23-138
GATE - REMOVAL, SWING
............23-138
GATE AJAR INDICATOR - DESCRIPTION
. . . 8J-20
GATE AJAR INDICATOR - OPERATION
.....8J-20
GATE BELTLINE WEATHERSTRIP -
INSTALLATION, SWING
...............23-186
GATE BELTLINE WEATHERSTRIP -
REMOVAL, SWING
...................23-186
GATE OPENING WEATHERSTRIP -
INSTALLATION, SWING
...............23-186
GATE OPENING WEATHERSTRIP -
REMOVAL, SWING
...................23-186
GAUGE - DESCRIPTION, ENGINE
TEMPERATURE
......................8J-18
GAUGE - DESCRIPTION, FUEL
...........8J-19GAUGE - OPERATION, ENGINE
TEMPERATURE......................8J-18
GAUGE - OPERATION, FUEL............8J-20
GEAR - DESCRIPTION.................19-13
GEAR - INSTALLATION, PINION
GEAR/RING..........................3-46
GEAR - OPERATION...................19-13
GEAR - REMOVAL, PINION GEAR/RING....3-44
GEAR/RING GEAR - INSTALLATION,
PINION.............................3-46
GEAR/RING GEAR - REMOVAL, PINION....3-44
GEAR/RING GEAR/TONE RING -
INSTALLATION, PINION............3-112,3-82
GEAR/RING GEAR/TONE RING -
REMOVAL, PINION...............3-110,3-79
GEARSHIFT CABLE - ADJUSTMENTS....21-130
GEARSHIFT CABLE - DIAGNOSIS AND
TESTING..........................21-128
GEARSHIFT CABLE - INSTALLATION.....21-129
GEARSHIFT CABLE - REMOVAL........21-128
GEAR/TONE RING - INSTALLATION,
PINION GEAR/RING...............3-112,3-82
GEAR/TONE RING - REMOVAL, PINION
GEAR/RING.....................3-110,3-79
GEARTRAIN - ASSEMBLY, PLANETARY . . . 21-160
GEARTRAIN - CLEANING, PLANETARY . . . 21-159
GEARTRAIN - DESCRIPTION,
PLANETARY........................21-157
GEARTRAIN - DISASSEMBLY,
PLANETARY........................21-159
GEARTRAIN - INSPECTION, PLANETARY . 21-159
GEARTRAIN - OPERATION, PLANETARY . . 21-157
GENERAL - WARNINGS.............8W-01-7
GENERATOR - DESCRIPTION...........8F-25
GENERATOR - INSTALLATION...........8F-26
GENERATOR - OPERATION.............8F-25
GENERATOR - REMOVAL...............8F-25
GENERATOR DECOUPLER - DIAGNOSIS
AND TESTING.......................8F-27
GENERATOR DECOUPLER PULLEY -
DESCRIPTION.......................8F-26
GENERATOR DECOUPLER PULLEY -
INSTALLATION.......................8F-30
GENERATOR DECOUPLER PULLEY -
OPERATION.........................8F-27
GENERATOR DECOUPLER PULLEY -
REMOVAL..........................8F-27
GENERATOR RATINGS, GAS ENGINES....8F-23
GLASS - INSTALLATION, DOOR . . 23-122,23-129,
23-172
GLASS - INSTALLATION, FLIP-UP.......23-136
GLASS - REMOVAL, DOOR......23-122,23-129,
23-172
GLASS - REMOVAL, FLIP-UP..........23-136
GLASS AJAR INDICATOR - DESCRIPTION . . 8J-21
GLASS AJAR INDICATOR - OPERATION . . . 8J-21
GLASS AJAR SWITCH - DESCRIPTION,
FLIP-UP............................8L-77
GLASS AJAR SWITCH - OPERATION,
FLIP-UP............................8L-77
GLASS HEATING GRID REPAIR -
STANDARD PROCEDURE, REAR..........8G-4
GLASS LATCH - INSTALLATION, FLIP-UP . 23-136
GLASS LATCH - REMOVAL, FLIP-UP.....23-136
GLASS PANEL - INSTALLATION........23-178
GLASS PANEL - REMOVAL............23-178
GLASS PANEL ADJUSTMENT,
ADJUSTMENTS - SUNROOF...........23-178
GLASS PANEL SEAL - INSTALLATION
....23-178
GLASS PANEL SEAL - REMOVAL
.......23-178
GLASS RELEASE SWITCH - DIAGNOSIS
AND TESTING, FLIP-UP
................8N-5
GLASS RUN CHANNEL - INSTALLATION
. 23-123,
23-130
GLASS RUN CHANNEL - REMOVAL
.....23-123,
23-130
GLASS SUPPORT CYLINDER -
INSTALLATION, FLIP-UP
..............23-139
GLASS SUPPORT CYLINDER -
REMOVAL, FLIP-UP
..................23-139
GLOVE BOX - INSTALLATION
..........23-148
GLOVE BOX - REMOVAL
..............23-148
GLOVE BOX LATCH - INSTALLATION
....23-148
GLOVE BOX LATCH - REMOVAL
........23-148
GLOVE BOX LATCH STRIKER -
INSTALLATION
......................23-149
GLOVE BOX LATCH STRIKER - REMOVAL
. 23-148GRAB HANDLE - INSTALLATION,
A-PILLAR TRIM.....................23-156
GRAB HANDLE - REMOVAL, A-PILLAR
TRIM.............................23-156
GRID - DESCRIPTION, REAR WINDOW
DEFOGGER..........................8G-5
GRID - DIAGNOSIS AND TESTING, REAR
WINDOW DEFOGGER..................8G-5
GRID - OPERATION, REAR WINDOW
DEFOGGER..........................8G-5
GRID REPAIR - STANDARD PROCEDURE,
REAR GLASS HEATING.................8G-4
GRILLE - INSTALLATION..............23-142
GRILLE - INSTALLATION, COWL........23-140
GRILLE - REMOVAL..................23-142
GRILLE - REMOVAL, COWL...........23-140
GRILLE OPENING REINFORCEMENT -
INSTALLATION......................23-142
GRILLE OPENING REINFORCEMENT -
REMOVAL.........................23-142
GROUND - STANDARD PROCEDURE,
TESTING FOR A SHORT TO..........8W-01-9
GROUND AND SPLICE INFORMATION -
DESCRIPTION, CONNECTOR..........8W-01-7
GROUND ON FUSES POWERING
SEVERAL LOADS - STANDARD
PROCEDURE, TESTING FOR A SHORT
TO..............................8W-01-9
GROUND STRAP - DESCRIPTION, RADIO
NOISE SUPPRESSION..................8A-9
GROUND STRAP - INSTALLATION,
RADIO NOISE SUPPRESSION...........8A-11
GROUND STRAP - OPERATION, RADIO
NOISE SUPPRESSION.................8A-10
GROUND STRAP - REMOVAL, RADIO
NOISE SUPPRESSION.................8A-10
GROUNDS - DESCRIPTION, POWER......8E-13
GUARD - DESCRIPTION, THERMAL......8F-20
GUARD - INSTALLATION, THERMAL......8F-20
GUARD - OPERATION, THERMAL........8F-20
GUARD - REMOVAL, THERMAL..........8F-20
GUIDE ASSEMBLY - INSTALLATION.....23-179
GUIDE ASSEMBLY - REMOVAL.........23-179
GUIDE SEALS - DESCRIPTION, VALVE . 9-29,9-38
GUIDES - DESCRIPTION, VALVE......9-19,9-30
HALF SHAFT - CAUTION................3-10
HALF SHAFT - DIAGNOSIS AND TESTING . . 3-10
HALF SHAFT - INSTALLATION............3-11
HALF SHAFT - REMOVAL...............3-10
HALF SHAFT, SPECIFICATIONS...........3-11
HANDLE - INSTALLATION, A-PILLAR
TRIM AND GRAB....................23-156
HANDLE - INSTALLATION, ASSIST......23-157
HANDLE - INSTALLATION, EXTERIOR . . . 23-123,
23-130,23-136
HANDLE - INSTALLATION, LATCH
RELEASE..........................23-120
HANDLE - REMOVAL, A-PILLAR TRIM
AND GRAB.........................23-156
HANDLE - REMOVAL, ASSIST..........23-157
HANDLE - REMOVAL, EXTERIOR . 23-123,23-130,
23-136
HANDLE - REMOVAL, LATCH RELEASE . . 23-120
HANDLING NON-DEPLOYED
SUPPLEMENTAL RESTRAINTS -
STANDARD PROCEDURE...............8O-6
HARNESS - DIAGNOSIS AND TESTING,
WIRING
..........................8W-01-7
HAZARD SWITCH - DESCRIPTION
.......8L-29
HAZARD SWITCH - INSTALLATION
.......8L-30
HAZARD SWITCH - OPERATION
.........8L-29
HAZARD SWITCH - REMOVAL
..........8L-30
HCU (HYDRAULIC CONTROL UNIT) -
DESCRIPTION
........................5-35
HCU (HYDRAULIC CONTROL UNIT) -
INSTALLATION
........................5-36
HCU (HYDRAULIC CONTROL UNIT) -
OPERATION
..........................5-35
HCU (HYDRAULIC CONTROL UNIT) -
REMOVAL
...........................5-36
HEAD - DESCRIPTION, CYLINDER
........9-30
HEAD COVER(S) - DESCRIPTION,
CYLINDER
...........................9-25
HEAD COVER(S) - INSTALLATION,
CYLINDER
.......................9-26,9-34
HEAD COVER(S) - REMOVAL, CYLINDER
. . 9-25,
9-34
KJINDEX 11
Description Group-Page Description Group-Page Description Group-Page

TANK - REMOVAL, FUEL...............14-25
TANK CHECK VALVE - DESCRIPTION,
FUEL..............................14-28
TANK CHECK VALVE - INSTALLATION,
FUEL..............................14-28
TANK CHECK VALVE - OPERATION, FUEL . . 14-28
TANK CHECK VALVE - REMOVAL, FUEL . . . 14-28
TANK SKID PLATE - INSTALLATION,
FUEL...............................13-9
TANK SKID PLATE - REMOVAL, FUEL......13-9
TASK MANAGER - DESCRIPTION........25-17
TASK MANAGER - OPERATION..........25-21
TCM QUICK LEARN - STANDARD
PROCEDURE........................8E-21
TEMP INDICATOR - DESCRIPTION,
TRANS.............................8J-33
TEMP INDICATOR - OPERATION, TRANS . . 8J-34
TEMP SENSOR - DESCRIPTION,
AMBIENT...........................8M-9
TEMP SENSOR - OPERATION, AMBIENT . . . 8M-9
TEMPERATURE GAUGE - DESCRIPTION,
ENGINE............................8J-18
TEMPERATURE GAUGE - OPERATION,
ENGINE............................8J-18
TEMPERATURE SENSOR - DESCRIPTION,
BATTERY...........................8F-24
TEMPERATURE SENSOR - DESCRIPTION,
ENGINE COOLANT.....................7-19
TEMPERATURE SENSOR - DESCRIPTION,
INTAKE AIR .........................14-36
TEMPERATURE SENSOR - DESCRIPTION,
TRANSMISSION.....................21-170
TEMPERATURE SENSOR - DIAGNOSIS
AND TESTING, AMBIENT...............8M-9
TEMPERATURE SENSOR -
INSTALLATION, BATTERY..............8F-24
TEMPERATURE SENSOR -
INSTALLATION, ENGINE COOLANT........7-21
TEMPERATURE SENSOR -
INSTALLATION, INTAKE AIR............14-38
TEMPERATURE SENSOR - OPERATION,
BATTERY...........................8F-24
TEMPERATURE SENSOR - OPERATION,
ENGINE COOLANT.....................7-20
TEMPERATURE SENSOR - OPERATION,
INTAKE AIR .........................14-36
TEMPERATURE SENSOR - OPERATION,
TRANSMISSION.....................21-170
TEMPERATURE SENSOR - REMOVAL,
BATTERY...........................8F-24
TEMPERATURE SENSOR - REMOVAL,
ENGINE COOLANT.....................7-20
TEMPERATURE SENSOR - REMOVAL,
INTAKE AIR .........................14-37
TEMPERATURE SENSOR CIRCUIT -
DIAGNOSIS AND TESTING, AMBIENT.....8M-9
TENSIONER - DESCRIPTION, SEAT BELT . . 8O-36
TENSIONER - OPERATION, SEAT BELT....8O-36
TERMINAL - INSTALLATION.........8W-01-14
TERMINAL - REMOVAL.............8W-01-14
TEST - DIAGNOSIS AND TESTING, FUEL
PRESSURE LEAK DOWN................14-3
TEST - DIAGNOSIS AND TESTING, FUEL
PUMP AMPERAGE....................14-16
TEST - DIAGNOSIS AND TESTING, FUEL
PUMP CAPACITY.....................14-15
TEST - DIAGNOSIS AND TESTING, FUEL
PUMP PRESSURE....................14-15
TEST - DIAGNOSIS AND TESTING,
HYDRAULIC PRESSURE...............21-79
TEST - DIAGNOSIS AND TESTING, ROAD . . . 8P-2
TEST - STANDARD PROCEDURE,
BUILT-IN INDICATOR..................8F-10
TEST - STANDARD PROCEDURE,
HYDROMETER.......................8F-11
TEST - STANDARD PROCEDURE,
IGNITION-OFF DRAW..................8F-14
TEST - STANDARD PROCEDURE, LOAD . . . 8F-12
TEST - STANDARD PROCEDURE,
OPEN-CIRCUIT VOLTAGE
...............8F-12
TEST - STANDARD PROCEDURE,
VERIFICATION
........................8O-8
TEST MODE - DESCRIPTION, CIRCUIT
ACTUATION
..........................25-2
TEST MODE - DESCRIPTION, STATE
DISPLAY
............................25-2
TESTER - STANDARD PROCEDURE,
USING MIDTRONICS ELECTRICAL
.......8F-15TETHER ANCHOR - DESCRIPTION, CHILD . 8O-13
TETHER ANCHOR - OPERATION, CHILD . . . 8O-13
THEFT SECURITY - DESCRIPTION,
VEHICLE............................8Q-1
THEFT SECURITY - OPERATION, VEHICLE . . 8Q-3
THEFT SECURITY SYSTEM - DIAGNOSIS
AND TESTING, VEHICLE................8Q-6
THERMAL GUARD - DESCRIPTION.......8F-20
THERMAL GUARD - INSTALLATION......8F-20
THERMAL GUARD - OPERATION.........8F-20
THERMAL GUARD - REMOVAL..........8F-20
THERMOSTAT - DIAGNOSIS AND
TESTING............................7-21
THERMOSTAT - OPERATION, ENGINE
COOLANT............................7-21
THREAD REPAIR - STANDARD
PROCEDURE, ALUMINUM..............21-81
THREADED HOLE REPAIR -
DESCRIPTION......................Intro.-4
THREADS - STANDARD PROCEDURE,
REPAIR DAMAGED OR WORN............9-9
THROTTLE BODY - DESCRIPTION........14-43
THROTTLE BODY - INSTALLATION.......14-44
THROTTLE BODY - OPERATION.........14-43
THROTTLE BODY - REMOVAL...........14-43
THROTTLE CONTROL CABLE -
INSTALLATION.......................14-46
THROTTLE CONTROL CABLE - REMOVAL . . 14-45
THROTTLE POSITION SENSOR -
DESCRIPTION.........................14-47
THROTTLE POSITION SENSOR -
INSTALLATION.......................14-48
THROTTLE POSITION SENSOR -
OPERATION.........................14-47
THROTTLE POSITION SENSOR -
REMOVAL..........................14-47
TIE ROD END - INSTALLATION..........19-16
TIE ROD END - REMOVAL..............19-16
TIE ROD END REMOVAL TOOL, SPECIAL
TOOLS - OUTER.....................19-15
TIME INDICATOR - DESCRIPTION, FULL . . . 8J-29
TIME INDICATOR - DESCRIPTION, PART . . 8J-29
TIME INDICATOR - OPERATION, FULL....8J-30
TIME INDICATOR - OPERATION, PART....8J-29
TIMING - DESCRIPTION, VALVE..........9-71
TIMING - OPERATION, VALVE............9-71
TIMING - SPECIFICATIONS, IGNITION......8I-2
TIMING BELT / CHAIN COVER(S) -
INSTALLATION........................9-76
TIMING BELT / CHAIN COVER(S) -
REMOVAL...........................9-74
TIMING CHAIN WEAR, STANDARD
PROCEDURE - MEASURING.............9-71
TIRE - INSTALLATION, SPARE...........22-9
TIRE - REMOVAL, SPARE...............22-8
TIRE INFLATION - DIAGNOSIS AND
TESTING............................22-7
TIRE NOISE OR VIBRATION - DIAGNOSIS
AND TESTING........................22-8
TIRE ROTATION - STANDARD
PROCEDURE.........................22-2
TIRE &TEMPORARY - DESCRIPTION,
SPARE..............................22-6
TIRE WEAR PATTERNS - DIAGNOSIS
AND TESTING........................22-8
TIRES - DESCRIPTION.................22-6
TIRES - DESCRIPTION, RADIAL-PLY.......22-6
TIRES - DESCRIPTION, REPLACEMENT....22-7
TIRES AND WHEEL RUNOUT -
DIAGNOSIS AND TESTING..............22-1
TO GROUND - STANDARD PROCEDURE,
TESTING FOR A SHORT.............8W-01-9
TO GROUND ON FUSES POWERING
SEVERAL LOADS - STANDARD
PROCEDURE, TESTING FOR A SHORT . . 8W-01-9
TO USE WIRING DIAGRAMS -
DESCRIPTION, HOW................8W-01-1
TOE ADJUSTMENT - STANDARD
PROCEDURE..........................2-5
TOE ADJUSTMENT - STANDARD
PROCEDURE, CAMBER, CASTER..........2-5
TOOL, SPECIAL TOOLS - OUTER TIE
ROD END REMOVAL..................19-15
TOOLS - 3.7L ENGINE, SPECIAL
..........9-15
TOOLS - 8 1/4 AXLE, SPECIAL
...........3-98
TOOLS - BASE BRAKES, SPECIAL
.........5-7
TOOLS - BODY, SPECIAL
................23-5
TOOLS - COOLING, SPECIAL
.............7-14TOOLS - FRONT AXLE, SPECIAL..........3-34
TOOLS - FRONT SUSPENSION, SPECIAL....2-8
TOOLS - FUEL SYSTEM, SPECIAL........14-6
TOOLS - OUTER TIE ROD END REMOVAL
TOOL, SPECIAL......................19-15
TOOLS - POWER DISTRIBUTION
SYSTEMS, SPECIAL................8W-97-2
TOOLS - POWER STEERING PUMP,
SPECIAL...........................19-20
TOOLS - REAR AXLE, SPECIAL...........3-63
TOOLS - RFE TRANSMISSION, SPECIAL . . 21-120
TOOLS - STEERING COLUMN, SPECIAL....19-8
TOOLS - WIRING/TERMINAL, SPECIAL . 8W-01-10
TOOLS, BATTERY SYSTEM - SPECIAL.....8F-7
TOOLS, SPECIFICATIONS - SPECIAL....3-12,3-6
TOOLS, SPECIFICATIONS - SPECIAL......8F-24
TOP COVER - INSTALLATION,
INSTRUMENT PANEL.................23-153
TOP COVER - REMOVAL, INSTRUMENT
PANEL............................23-152
TORQUE - SPECIFICATIONS.............13-6
TORQUE CHART, SPECIFICATIONS . . 19-15,19-19,
19-8
TORQUE CHART, SPECIFICATIONS.....2-17,2-8
TORQUE CONVERTER - DESCRIPTION . . . 21-162
TORQUE CONVERTER - INSTALLATION . . . 21-167
TORQUE CONVERTER - OPERATION.....21-166
TORQUE CONVERTER - REMOVAL......21-167
TORQUE, EXCEPT DIESEL..............8F-23
TORQUE, GAS POWERED..............8F-38
TORQUE, IGNITION SYSTEM.............8I-3
TORQUE REFERENCES - DESCRIPTION . . Intro.-7
TORQUE, SPECIFICATIONS...............5-7
TORQUE, SPECIFICATIONS..............7-13
TORQUE, SPECIFICATIONS.............25-26
TORQUE, SPECIFICATIONS..............9-12
TORQUE, SPECIFICATIONS..............14-5
TORQUE, SPEED CONTROL.............8P-2
TOUCH-UP - DESCRIPTION, PAINT......23-163
TOW CONNECTOR - INSTALLATION,
TRAILER...........................8L-61
TOW CONNECTOR - REMOVAL, TRAILER . . 8L-61
TOW HOOK - INSTALLATION, FRONT......13-8
TOW HOOK - INSTALLATION, REAR.......13-8
TOW HOOK - REMOVAL, FRONT..........13-8
TOW HOOK - REMOVAL, REAR...........13-8
TOW RELAY - DESCRIPTION, TRAILER....8L-61
TOW RELAY - DIAGNOSIS AND TESTING,
TRAILER...........................8L-62
TOW RELAY - INSTALLATION, TRAILER . . . 8L-64
TOW RELAY - OPERATION, TRAILER.....8L-62
TOW RELAY - REMOVAL, TRAILER.......8L-63
TOW WIRING - DESCRIPTION, TRAILER . . 8L-64
TOWING - STANDARD PROCEDURE........0-6
TRACK - DESCRIPTION, SEAT..........8N-15
TRACK - DIAGNOSIS AND TESTING,
SEAT ..............................8N-16
TRACK - INSTALLATION, SEAT.........23-168
TRACK - INSTALLATION, SEAT..........8N-16
TRACK - OPERATION, SEAT............8N-15
TRACK - REMOVAL, SEAT.............23-168
TRACK - REMOVAL, SEAT..............8N-16
TRAC-LOK - ASSEMBLY, DIFFERENTIAL . . . 3-109,
3-77
TRAC-LOK - CLEANING, DIFFERENTIAL . . . 3-109,
3-77
TRAC-LOK - DISASSEMBLY,
DIFFERENTIAL...................3-107,3-75
TRAC-LOK - INSPECTION, DIFFERENTIAL . 3-109,
3-77
TRAC-LOKT- DIAGNOSIS AND TESTING . . 3-106,
3-74
TRAILER HITCH - INSTALLATION.........13-9
TRAILER HITCH - REMOVAL.............13-9
TRAILER TOW CONNECTOR -
INSTALLATION.......................8L-61
TRAILER TOW CONNECTOR - REMOVAL . . 8L-61
TRAILER TOW RELAY - DESCRIPTION....8L-61
TRAILER TOW RELAY - DIAGNOSIS AND
TESTING...........................8L-62
TRAILER TOW RELAY - INSTALLATION . . . 8L-64
TRAILER TOW RELAY - OPERATION......8L-62
TRAILER TOW RELAY - REMOVAL
.......8L-63
TRAILER TOW WIRING - DESCRIPTION
. . . 8L-64
TRANS COOLER - DESCRIPTION
.........7-32
TRANS TEMP INDICATOR -
DESCRIPTION
.......................8J-33
TRANS TEMP INDICATOR - OPERATION
. . . 8J-34
KJINDEX 27
Description Group-Page Description Group-Page Description Group-Page